Thermal penetration and arc length controllable electrosurgical pencil

ABSTRACT

An electrosurgical pencil is provided, which includes an elongated housing, an electrocautery electrode supported within the housing and extending distally from the housing. The electrocautery electrode is connected to a source of electrosurgical energy. The pencil also includes at least one voltage divider network supported on the housing and electrically connected to the source of electrosurgical energy for controlling intensity, frequency, and/or mode of electrosurgical energy being delivered to the electrocautery electrode.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.12/275,290, filed Nov. 21, 2008, now U.S. Pat. No. 8,235,987, whichclaims the benefit of, and priority to, U.S. Provisional PatentApplication Ser. No. 60/992,413, entitled “THERMAL PENETRATION AND ARCLENGTH CONTROLLABLE ELECTROSURGICAL PENCIL,” filed Dec. 5, 2007, theentire content of each of the applications identified above beingincorporated by reference herein.

BACKGROUND

1. Technical Field

The present disclosure relates generally to electrosurgical instrumentsand, more particularly, to an electrosurgical pencil having a pluralityof hand-accessible variable controls.

2. Background of Related Art

Electrosurgical instruments have become widely used by surgeons inrecent years. Accordingly, a need has developed for equipment andinstruments that are easy to handle, are reliable and are safe in anoperating environment. By and large, most electrosurgical instrumentsare hand-held instruments, e.g., an electrosurgical pencil, thattransfer radio-frequency (RF) electrical or electrosurgical energy to atissue site. The electrosurgical energy is returned to theelectrosurgical source via a return electrode pad positioned under apatient (i.e., a monopolar system configuration) or a smaller returnelectrode positionable in bodily contact with or immediately adjacent tothe surgical site (i.e., a bipolar system configuration). The waveformsproduced by the RF source yield a predetermined electrosurgical effectknown generally as electrosurgical cutting and fulguration.

As used herein the term “electrosurgical pencil” is intended to includeinstruments having a handpiece that is attached to an active electrodeand is used to cauterize, coagulate and/or cut tissue. Typically, theelectrosurgical pencil may be operated by a handswitch or a foot switch.The active electrode is an electrically conducting element, which isusually elongated and may be in the form of a thin flat blade with apointed or rounded distal end. Alternatively, the active electrode mayinclude an elongated narrow cylindrical needle that is solid or hollowwith a flat, rounded, pointed or slanted distal end. Typicallyelectrodes of this sort are known in the art as “blade”, “loop” or“snare”, “needle” or “ball” electrodes.

As mentioned above, the handpiece of the electrosurgical pencil isconnected to a suitable electrosurgical energy source (i.e., generator)that produces the radio-frequency electrical energy necessary for theoperation of the electrosurgical pencil. In general, when an operationis performed on a patient with an electrosurgical pencil, electricalenergy from the electrosurgical generator is conducted through theactive electrode to the tissue at the site of the operation and thenthrough the patient to a return electrode. The return electrode istypically placed at a convenient place on the patient's body and isattached to the generator by a conductive material. Typically, thesurgeon activates the controls on the electrosurgical pencil to selectthe modes/waveforms to achieve a desired surgical effect.

The power parameters are typically controlled from outside the sterilefield, which requires an intermediary like a circulating nurse to makesuch adjustment.

A typical electrosurgical generator has numerous controls for selectingan electrosurgical output. For example, the surgeon can select varioussurgical “modes” to treat tissue: cut, blend (blend levels 1-3), lowcut, desiccate, fulgurate, spray, etc. The surgeon also has the optionof selecting a range of power settings. As can be appreciated, thisgives the surgeon a great deal of variety when treating tissue. However,so many options also tend to complicate simple surgical procedures andmay lead to confusion. Moreover, surgeons typically follow presetcontrol parameters and stay within known modes, frequencies, and powersettings.

SUMMARY

The present disclosure is directed to an electrosurgical pencil havingvariable controls. In accordance with one aspect of the presentdisclosure the electrosurgical pencil includes an elongated housing andan electrocautery electrode supported within the housing and extendingdistally from the housing, the electrocautery electrode being connectedto a source of electrosurgical energy. At least one voltage dividernetwork (hereinafter “VDN”) is also supported on the housing and, iselectrically connected to the source of electrosurgical energy forcontrolling a frequency, intensity, and/or mode of electrosurgicalenergy being delivered to the electrocautery electrode.

In another embodiment, an electrosurgical pencil is disclosed having anelongated housing and an electrocautery electrode supported within thehousing and extending distally therefrom. The electrocautery electrodeis operable to connect to a source of electrosurgical energy. At leastone voltage divider network is supported on the housing and is operableto electrically connect to the source of electrosurgical energy forcontrolling the frequency, intensity, and/or mode of electrosurgicalenergy being delivered to the electrocautery electrode. Theelectrosurgical pencil further includes a frequency controller slidablysupported on the housing. The frequency controller is configured toselectively actuate the voltage divider network(s) and provide a tactilefeedback to a user of the electrosurgical pencil as the frequencycontroller is moved relative to the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the present disclosure are described herein withreference to the drawings wherein:

FIG. 1 is a perspective view of an electrosurgical pencil in accordancewith the present disclosure;

FIG. 2A is a partially exploded, perspective view of the proximal end ofthe electrosurgical pencil of FIG. 1;

FIG. 2B is a partially exploded, perspective view of the distal end ofthe electrosurgical pencil of FIG. 1;

FIG. 3 is an exploded perspective view of the electrosurgical pencil ofFIGS. 1 and 2;

FIG. 4 is a partially exploded, side elevational view of an alternativeembodiment of the electrosurgical pencil of FIGS. 1-3;

FIG. 5 is a top plan view of an electrosurgical pencil according toanother embodiment of the present disclosure;

FIG. 6 is a side elevational view of the electrosurgical pencil of FIG.5;

FIG. 7 is a front perspective view of a distal end portion of anelectrosurgical pencil according to yet another embodiment of thepresent disclosure;

FIG. 8 is a front perspective view of a distal end portion of anelectrosurgical pencil according to still another embodiment of thepresent disclosure;

FIG. 9 is an enlarged perspective view of a portion of anelectrosurgical pencil illustrating a set of exemplary switches disposedthereon;

FIG. 10 is an enlarged perspective view of a portion of anelectrosurgical pencil illustrating another set of exemplary switchesdisposed thereon;

FIG. 11 is a perspective view of the switch of FIG. 10; and

FIG. 12 is a schematic illustration of a voltage divider networkaccording to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Particular embodiments of the present disclosure are describedhereinbelow with reference to the accompanying drawings. As used herein,the term “distal” refers to that portion which is further from the userwhile the term “proximal” refers to that portion which is closer to theuser or surgeon. In the following description, well-known functions orconstructions are not described in detail to avoid obscuring the presentdisclosure in unnecessary detail.

In general, the present disclosure is directed to an electrosurgicalpencil including an electrocautery electrode and at least one VDNelectrically connected to a source of electrosurgical energy forcontrolling at least one of a frequency, an intensity, and a mode ofelectrosurgical energy being delivered to the electrocautery electrode.

FIG. 1 sets forth a perspective view of an electrosurgical pencilconstructed in accordance with one embodiment of the present disclosureand generally referenced by numeral 10. While the following descriptionwill be directed towards electrosurgical pencils for the purposes ofillustration, the features and concepts (or portions thereof) of thepresent disclosure can be applied to any electrosurgical typeinstrument, e.g., forceps, suction coagulator, vessel sealers, etc.

As seen in FIGS. 1-3, electrosurgical pencil 10 includes an elongatedhousing 2 configured and adapted to support a blade receptacle 4 at adistal end 3 thereof which, in turn, receives a replaceableelectrocautery end effector 6 in the form of a loop and/or bladetherein. Electrocautery blade 6 is understood to include a planar blade,a loop, a needle and the like. A distal end portion 8 of blade 6 extendsdistally from receptacle 4 while a proximal end portion 11 (see FIG. 3)of blade 6 is retained within distal end 3 of housing 2. Electrocauteryblade 6 may be fabricated from any suitable conductive type material,such as, for example, stainless steel, or is coated with an electricallyconductive material.

As shown, electrosurgical pencil 10 is coupled to a conventionalelectrosurgical generator “G” via a cable 12. Cable 12 includes atransmission wire 14 (see FIG. 3), which electrically interconnectselectrosurgical generator “G” with proximal end portion 11 ofelectrocautery blade 6. Cable 12 further includes control wires 16,which electrically interconnect mode activation switches (as will bedescribed in greater detail below), supported on an outer surface 7 ofhousing 2, with electrosurgical generator “G”. For the purposes hereinthe terms “switch” or “switches” includes electrical actuators,mechanical actuators, electro-mechanical actuators (rotatable actuators,pivotable actuators, toggle-like actuators, buttons, etc.) or opticalactuators.

Turning back to FIGS. 1-3, as mentioned above, electrosurgical pencil 10further includes at least one activation switch. In the illustratedembodiment, electrosurgical pencil 10 includes three activation switches24 a-24 c, each of which are supported on an outer surface 7 of housing2. Each activation switch 24 a-24 c is operatively connected to alocation on a tactile element 26 a-26 c (e.g., a snap-dome is shown)which, in turn, controls the transmission of RF electrical energysupplied from generator “G” to electrosurgical blade 6. Moreparticularly, tactile elements 26 a-26 c are operatively connected to avoltage divider network 27 (hereinafter “VDN 27”), which forms a switchclosure (e.g., here shown as a film-type potentiometer). For thepurposes herein, the term “voltage divider network” relates to any knownform of resistive, capacitive or inductive switch closure (or the like)that determines the output voltage across a voltage source (e.g., one oftwo impedances) connected in series. A “voltage divider” as used hereinrelates to a number of resistors connected in series that are providedwith taps at certain points to make available a fixed or variablefraction of the applied voltage.

In use, depending on which activation switch 24 a-24 c is depressed arespective switch 26 a-26 c is pressed into contact with VDN 27 and acharacteristic signal is transmitted to electrosurgical generator “G”via control wires 16. Control wires 16 a-16 c are electrically connectedto switches 26 a-26 c via a terminal 15 (see FIGS. 2 and 3) operativelyconnected to VDN 27. In embodiments, electrosurgical generator “G” maybe used in conjunction with the device wherein generator “G” includes acircuit for interpreting and responding to the VDN settings.

Activation switches 24 a-24 c are configured and adapted to control themode and/or “waveform duty cycle” to achieve a desired surgical intent.For example, first activation switch 24 a can be set to deliver acharacteristic signal to electrosurgical generator “G” that in turntransmits a duty cycle and/or waveform shape that produces a cuttingand/or dissecting effect/function. Meanwhile, second activation switch24 b can be set to deliver a characteristic signal to electrosurgicalgenerator “G” that in turn transmits a duty cycle and/or waveform shapethat produces a blending effect/function (e.g., a combination of adissecting and a hemostatic effect/function). Finally, third activationswitch 24 c can be set to deliver a characteristic signal toelectrosurgical generator “G” that in turn transmits a duty cycle and/orwaveform shape that produces a hemostatic effect/function.

Fourth control wire 16 d (i.e., a return control wire) is connected toproximal end 11 of electrocautery blade 6. This prevents electrosurgicalcurrent, induced in control wires 16 a-16 c, from flowing throughactivation switches 24 a-24 c to electrocautery blade 6. This in turn,increases the longevity and life of switches 24 a-24 c.

Electrosurgical pencil 10 further includes an intensity controller 28slidingly supported on housing 2. Intensity controller 28 includes apair of nubs 29 a, 29 b, which are slidingly supported, one each, inrespective guide channels 30 a, 30 b, formed in outer surface 7 ofhousing 2 on either side of activations switches 24 a-24 c. By providingnubs 29 a, 29 b on either side of activation switches 24 a-24 c,controller 28 can be easily manipulated by either hand of the user orthe same electrosurgical pencil can be operated by a right-handed or aleft-handed user.

In embodiments, intensity controller 28 may be a slide potentiometerwherein nubs 29 a, 29 b have a first position (e.g., proximal-mostposition closest to cable 12) corresponding to a relative low intensitysetting, a second position (e.g., a distal-most position closest toelectrocautery end effector 6) corresponding to a relative highintensity setting, and a plurality of intermediate positionscorresponding to intermediate intensity settings. In embodiments, theintensity settings from proximal end to distal end may be reversed (e.g.high to low). Nubs 29 a, 29 b of intensity controller 28 andcorresponding guide channels 30 a, 30 b may be provided with a series ofcooperating discreet or dented positions defining a series of positions(e.g., five) to allow easy selection of the output intensity from thelow intensity setting to the high intensity setting. The series ofcooperating discreet or detented positions also provide the surgeon witha degree of tactile feedback. As best seen in FIG. 2, intensitycontroller 28 can include a series of indicia 31 provided thereon, whichare visible through guide channels 30 a, 30 b. Indicia 31 may be aseries of numbers (e.g., numbers 1-5) that reflect the level ofintensity that is to be transmitted. Alternatively, level indicators maybe printed alongside the sides of guide channels 30 a, 30 b along whichnubs 29 a, 29 b slide.

Intensity controller 28 is configured and adapted to adjust the powerparameters (e.g., voltage, power and/or current intensity) and/or thepower verses impedance curve shape to affect the perceived outputintensity. For example, the greater intensity controller 28 is displacedin a distal direction the greater the level of the power parameterstransmitted to electrocautery blade 6. Conceivably, current intensitiescan range from about 60 mA to about 240 mA when using an electrosurgicalblade and having a typical tissue impedance of about 2K ohms. Anintensity level of 60 mA provides very light and/or minimalcutting/dissecting/hemostatic effects. An intensity level of 240 mAprovides very aggressive cutting/dissecting/hemostatic effects.Accordingly, the optimal range of current intensity is from about 100 mAto about 200 mA at 2K ohms.

In embodiments, the intensity settings are preset and selected from alook-up table based on a choice of electrosurgicalinstruments/attachments, desired surgical effect, surgical specialtyand/or surgeon preference. The selection may be made automatically orselected manually by the user. The intensity values may be predeterminedor adjusted by the user.

Electrosurgical pencil 10 further includes a frequency controller 35slidingly supported on housing 2. Frequency controller 35 includes a nub36 that is slidingly supported in a guide channel 37 formed in outersurface 7 of housing 2 proximal to activation switches 24 a-24 c.

In embodiments, frequency controller 35 may be a slide potentiometerwherein nub 36 has a first position (e.g., a proximal-most positionclosest to cable 12) corresponding to a relative low frequency setting,a second position (e.g., a distal-most position closest toelectrocautery end effector 6) corresponding to a relatively highfrequency setting, and a plurality of intermediate positionscorresponding to intermediate frequency settings. Any one of theplurality of intermediate positions may correspond to the “park”position, as discussed above. that corresponds to a standard and/orpre-determined frequency setting.

In embodiments, nub 36 of frequency controller 35 and correspondingguide channel 37 may be provided with a series of cooperating discreetor dented positions defining a series of positions (e.g., fivepositions) to allow easy selection of the output frequency from the lowfrequency setting to the high frequency setting. The series ofcooperating discreet or detented positions also provide the surgeon witha degree of tactile feedback. As best seen in FIG. 2, frequencycontroller 35 may include a series of indicia 38 provided thereon thatare visible through guide channel 37. Indicia 38 may be a series ofnumbers (e.g., numbers 1-5) that reflect the level of frequency that isto be transmitted. Alternatively, level indicators may be printedalongside the side of guide channel 37 along which nub 36 slides.

Frequency controller 35 is configured and adapted to adjust thefrequency parameter to affect the perceived RF output of generator “G.”By way of example, the greater frequency controller 35 is displaced in adistal direction the greater the level of the frequency parameter of theenergy transmitted to electrocautery blade 6. As frequency is increasedfrom about 470 kHz to about 1 MHz, thermal penetration decreases and arclength increases. Thus, a frequency level of 470 kHz provides for deepthermal penetration and a relatively short arc length while a frequencylevel of 1 MHz provides for superficial thermal penetration and arelatively long arc length. Accordingly, the user would utilize thefrequency controller 35 to select the lower 470 kHz level of frequencyif deep thermal penetration is required to provide the desired surgicaleffect without the need for a long arc length. Conversely, the userwould utilize the frequency controller 35 to select the higher 1 MHzlevel of frequency if superficial thermal penetration and a longer arclength are required to provide the desired surgical effect.

In embodiments, the frequency settings may be preset and selected from alook-up table based on a choice of electrosurgicalinstruments/attachments, desired surgical effect, surgical specialtyand/or surgeon preference. The selection may be made automatically orselected manually by the user. The frequency values may be predeterminedor adjusted by the user.

With reference to FIG. 12, in accordance with an embodiment of thepresent disclosure, a voltage divider network (VDN) 27, forinter-connecting control wires 16 a-16 d to activation andelectrosurgical switches 24 a-24 c and electrocautery power wire 14 toblade 6, is shown. VDN 27 includes a first transmission line 27 a,electrically connected to one of control wires 16 a-16 d, to operate thevarious frequencies of electrosurgical pencil 10. VDN 27 includes asecond transmission line 27 b, electrically connected to one of controlwires 16 a-16 d, to operate the various modes of electrosurgical pencil10. VDN 27 includes a third transmission line 27 c, electricallyconnected to one of control wires 16 a-16 d, to operate the variousintensities of electrosurgical pencil 10. VDN 27 includes a fourth andfifth transmission line 27 d and 27 e, respectively, to apply a voltageacross VDN 27. For example, fourth transmission line 27 d may beisolated or grounded and transmission line 27 e may transmit +5 volts.

In the illustrated embodiment, VDN 27 includes a plurality of resistors“R1” (e.g., 6 resistors), connected in a first series betweentransmission line 27 d and transmission line 27 e. In embodiments,resistors “R1” may combine to total about 1000 ohms of resistance. Thefirst series of resistors “R1” is selectively actuatable by intensitycontroller 28 at a plurality of locations along the length thereof.These locations along the length of the first series of resistors “R1”are represented as a first set of switches “S1 a-S1 e.” In operation, asintensity controller 28 is moved along the first series of resistors“R1,” the value of the resistance of the first series of resistors “R1”is changed. The change of the resistance value of the first series ofresistors “R1” is represented in FIG. 12 as the closing of a switch “S1a-S1 e.” The change in resistance of the first series of resistors “R1”causes a change in voltage that is measured by electrosurgical generator“G” that, in turn, transmits an RF energy at a unique intensity toelectrosurgical pencil 10.

When intensity controller 28 is moved to a third of middle positionalong the first series of resistors “R1,” corresponding to switch “S1c,” a “park position” is established in which no resistance is present.Accordingly, electrosurgical generator “G” measures a maximum voltagevalue of zero volts.

VDN 27 further includes a plurality of resistors “R2” (e.g., fourresistors), connected in a second series between transmission line 27 dand transmission line 27 e. In embodiments, resistors “R2” may combineto total about 1000 ohms of resistance. The second series of resistors“R2” is selectively actuatable by any one of activation buttons 24 a-24c. The location where the second series of resistors “R2” is actuated isrepresented by as a second set of switches “S2 a-S2 c.” In operation,depending which switch “S2 a-S2 c” is closed, by actuation of aparticular activation switch 24 a-24 c, the value of the resistance ofthe second series of resistors “R2” is changed. The change of theresistance value of the second series of resistors “R2” causes a changein voltage that is measured by electrosurgical generator “G” that, inturn, activates and transmits a different mode of operation toelectrosurgical pencil 10.

VDN 27 further includes a plurality of resistors “R3” (e.g., sixresistors), connected in a third series between transmission line 27 dand transmission line 27 e. In embodiments, resistors “R3” may combineto total about 1000 ohms of resistance. The third series of resistors“R3” is selectively actuatable by frequency controller 35 at a pluralityof locations along the length thereof. These locations along the lengthof the third series of resistors “R3” are represented as a third set ofswitches “S3 a-S3 e.” In operation, as frequency controller 35 is movedalong the third series of resistors “R3,” the value of the resistance ofthe third series of resistors “R3” is changed. The change of theresistance value of the third series of resistors “R3” is represented inFIG. 12 as the closing of a switch “S3 a-S3 e.” The change in resistanceof the third series of resistors “R3” causes a change in voltage that ismeasured by electrosurgical generator “G” that, in turn, transmits an RFenergy at a unique intensity to electrosurgical pencil 10.

When frequency controller 35 is moved to a third of middle positionalong the third series of resistors “R3,” corresponding to switch “S3c,” a “park position” is established in which no resistance is present.Accordingly, electrosurgical generator “G” measures a maximum voltagevalue of zero volts. In embodiments, electrosurgical generator “G” mayinterpret a measured voltage value of zero volts as a signal to transmitRF energy at a standard and/or predetermined level to electrosurgicalpencil 10.

In operation, if more than one activation button 24 a-24 c is actuatedsimultaneously (i.e., a “multi-key activation” scenario),electrosurgical generator “G” will measure a unique voltage that doesnot correspond to any preset known voltage stored therein and thus doesnot activate or transmit any mode of operation to electrosurgical pencil10.

In use, depending on which activation button 24 a-24 c is depressed arespective switch 26 a-26 c is pressed into contact with VDN 27. Thedepressed activation button 24 a-24 c electrically engages juxtaposedelectrical contacts of VDN 27 thereby changing the value of the secondseries of resistors “R2.” Depending on the value of the resistance ofthe second series of resistors “R2” a characteristic voltage isgenerated and measured by electrosurgical generator “G” via transmissionline 27 b and one of control wires 16 a-16 d. (See FIGS. 3 and 12).

In order to vary the intensity of the power parameters ofelectrosurgical pencil 10, the surgeon displaces intensity controller 28as described above, thereby changing the value of the first series ofresistors “R1.” Depending on the value of the resistance of the firstseries of resistors “R1,” a characteristic voltage is generated andmeasured by electrosurgical generator “G” via third transmission line 27c and one of control wires 16 a-16 d. (See FIGS. 3 and 12).

In embodiments, a VDN (not explicitly shown) separate from VDN 27 may beprovided for any one of the first series, second series, and thirdseries of resistors “R1,” “R2,” and “R3” or any combination thereof. Inthis configuration, an independent voltage comparator circuit (notexplicitly shown) may be provided to permit bi-directional communicationbetween two or more VDNs. In this manner, each VDN may reference thevoltage and, thus, the unique mode/frequency/duty cycle of the RF energybeing transmitted to electrocautery blade 6.

Also as depicted in FIG. 12, transmission wire 14 is isolated from orotherwise completely separate from VDN 27. In particular, transmissionwire 14 extends directly from the RF input or generator “G” to the RFoutput or to electrocautery blade 6.

The hemostatic effect/function may be defined as having waveforms with aduty cycle from about 1% to about 12%. The blending effect/function maybe defined as having waveforms with a duty cycle from about 12% to about75%. The cutting and/or dissecting effect/function may be defined ashaving waveforms with a duty cycle from about 75% to about 100%. It isimportant to note that these percentages are approximated and may becustomized to deliver the desired surgical effect for various tissuetypes and characteristics.

In operation and depending on the particular electrosurgical functiondesired, the surgeon depresses one of activation switches 24 a-24 c, inthe direction indicated by arrow “Y” (see FIG. 1) thereby urging acorresponding switch 26 a-26 c against VDN 27 and thereby transmitting arespective characteristic signal to electrosurgical generator “G”. Forexample, the surgeon can depress activation switch 24 a to perform acutting and/or dissecting function, activation switch 24 b to perform ablending function, or activation switch 24 c to perform a hemostaticfunction. In turn, generator “G” transmits an appropriate waveformoutput to electrocautery blade 6 via transmission wire 14.

In order to vary the intensity of the power parameters ofelectrosurgical pencil 10, the surgeon displaces intensity controller 28in the direction indicated by double-headed arrow “X”. As mentionedabove, the intensity can be varied from approximately 60 mA for a lighteffect to approximately 240 mA for a more aggressive effect. Forexample, by positioning nubs 29 a, 29 b of intensity controller 28closer to the proximal-most end of guide channels 30 a, 30 b (i.e.,closer to cable 12) a lower intensity level is produced and bypositioning nubs 29 a, 29 b of intensity controller 28 closer to thedistal-most end of guide channels 30 a, 30 b (i.e., closer toelectrocautery end effector 6) a larger intensity level is producedresulting in a more aggressive effect being produced. In embodiments,when nubs 29 a, 29 b of intensity controller 28 are positioned at theproximal-most end of guide channels 30 a, 30 b, VDN 27 is set to a nulland/or open position. Electrosurgical pencil 10 may be shipped withintensity controller 28 set to the null and/or open positions. Inembodiments, the frequency settings from proximal end to distal end maybe reversed (e.g., high to low).

In order to vary the frequency of the energy transmitted byelectrosurgical generator “G” to pencil 10, the surgeon displacesfrequency controller 35 in the direction indicated by double headedarrow “X.” As mentioned above, the frequency may be varied from about 1MHz for superficial thermal penetration and a long arc length and 470kHz for deep thermal penetration and a short arc length. For example, bypositioning nub 36 of frequency controller 35 closer to the distal-mostend of guide channel 37 (i.e., closer to electrocautery end effector 6)a higher frequency level is produced and by positioning nub 36 offrequency controller 35 closer to the distal-most end of guide channel37 (i.e., closer to cable 12) a lower frequency level is producedresulting in deeper thermal penetration. In embodiments, when nub 36 offrequency controller 35 is positioned at the proximal-most end of guidechannel 37, VDN 27 is set to a null and/or open position.Electrosurgical pencil 10 may be shipped with frequency controller 35set to the null and/or open position.

In embodiments, intensity controller 28 may control the intensity levelof the electrosurgical energy transmitted by all three activationswitches 24 a-24 c, simultaneously. That is, as nubs 29 a, 29 b ofintensity controller 28 are positioned relative to guide channels 30 a,30 b, the intensity level of the electrosurgical energy transmitted toall three activation switches 24 a-24 c is set to the same value ofslide potentiometer or intensity controller 28. Similarly, frequencycontroller 35 may control the frequency level of the electrosurgicalenergy transmitted by all three activation switches 24 a-24 c,simultaneously. That is, as nub 36 of frequency controller 35 ispositioned relative to guide channel 37, the frequency level of theelectrosurgical energy transmitted to all three activation switches 24a-24 c is set to the same value of slide potentiometer or frequencycontroller 35.

As a safety precaution, when electrosurgical pencil 10 is changed fromone mode to another, intensity controller 28 and frequency controller 35may be configured such that each must be reset (i.e., nubs 29 a, 29 b,36 re-positioned to the proximal-most end of guide channels 30 a, 30 b,37, thus setting VDN 27 to the null and/or open position). After beingreset, intensity controller 28 and frequency controller 35 may beadjusted as needed to the desired and/or necessary intensity level andfrequency level respectively, for the mode selected.

In embodiments, VDN 27 may also include an algorithm that stores thelast intensity level and/or frequency level setting for each mode. Inthis manner, intensity controller 28 and frequency controller 35 do nothave to be reset to the last operative value when the particular mode isre-selected.

The combination of placing VDN 27 and fourth control wire 16 d inelectrosurgical pencil 10 essentially places the entire resistor networkof the electrosurgical system (e.g., electrosurgical pencil 10 and thesource of electrosurgical energy “G”) within electrosurgical pencil 10.Conventional electrosurgical systems typically include a currentlimiting resistor disposed within the electrosurgical pencil, foractivating the electrosurgical pencil, and a second resistor networkdisposed in the source of electrosurgical energy, for controlling theintensity of the electrosurgical energy transmitted. In accordance withthe present disclosure, all three resistor networks are disposed withinelectrosurgical pencil 10, namely, the first resistor network asevidenced by frequency controller 35, the second resistor network asevidenced by activation switches 24 a-24 c, and the third resistornetwork as evidenced by intensity controller 28.

As described above, intensity controller 28 and frequency controller 35can be configured and adapted to provide a degree of tactile feedback.Alternatively, audible feedback can be produced from intensitycontroller 28 (e.g., a “click”), from electrosurgical energy source “G”(e.g., a “tone”) and/or from an auxiliary sound-producing device such asa buzzer (not explicitly shown).

As seen in FIGS. 1 and 3, intensity controller 28 and activationswitches 24 a-24 c are supported in a recess 9 formed in outer wall 7 ofhousing 2. In embodiments, activation switches 24 a-24 c may bepositioned at a location where the fingers of the surgeon would normallyrest when electrosurgical pencil 10 is held in the hand of the surgeonwhile nubs 29 a, 29 b of intensity controller 28 are placed at locationsthat would not be confused with activation switches 24 a-24 c.Alternatively, nubs 29 a, 29 b of intensity controller 28 are positionedat locations where the fingers of the surgeon would normally rest whenelectrosurgical pencil 10 is held in the hand of the surgeon whileactivation switches 24 a-24 c are placed at locations that would not beconfused with nubs 29 a, 29 b of intensity controller 28. In addition,recess 9 formed in outer wall 7 of housing 2 advantageously minimizesinadvertent activation (e.g., depressing, sliding and/or manipulating)of activation switches 24 a-24 c and intensity controller 28 while inthe surgical field and/or during the surgical procedure. In embodiments,frequency controller 35 may be embodied in a “two-nub” configurationsubstantially similar to intensity controller 28. Likewise, intensitycontroller 28 may be embodied in a “single-nub” configurationsubstantially similar to frequency controller 35. In this configuration,the placement of frequency controller 35 and intensity controller 28 maybe reversed. That is, frequency controller 35 may be supported withinouter surface 7 of housing 2 on either side of activations switches 24a-24 c (e.g., in guide channels 30 a and 30 b) and intensity controller28 may be slidingly supported proximal to recess 9 (e.g., in guidechannel 37). Additionally or alternatively, a second guide channel (notexplicitly shown) may be formed in outer surface 7 of housing 2 proximalto activation switches 24 a-24 c. The second guide channel may bepositioned in parallel to guide channel 37 and in spaced relationthereto (e.g., similar to guide channels 30 a and 30 b) to cooperativelysupport a “two-nub” embodiment of either intensity controller 28 orfrequency controller 35.

As seen in FIG. 3, electrosurgical pencil 10 includes a molded/contouredhand grip 5, which substantially surrounds the distal and proximal endsof housing 2 as well as the underside of housing 2. Contoured hand grip5 is shaped and dimensioned to improve the handling of electrosurgicalpencil 10 by the surgeon. Accordingly, less pressure and gripping forceis required to use and/or operate electrosurgical pencil 10 therebypotentially reducing the fatigue experienced by the surgeon and toprevent movement of electrosurgical pencil 10 during proximal and distaladjustments of nubs 29 a and 29 b.

As seen in FIG. 4, an alternative embodiment of electrosurgical pencil10 is shown generally as 100. Electrosurgical pencil 100 is similar toelectrosurgical pencil 10 and will only be discussed in detail to theextent necessary to identify differences in construction and operation.As seen in FIG. 4, electrosurgical pencil 100 includes a plurality ofactivation switches 124 a-124 c, each of which are supported on an outersurface 107 of housing 102. Each activation switch 124 a-124 c isoperatively connected to a respective switch 126 a-126 c which, in turn,controls the transmission of RF electrical energy supplied fromgenerator “G” to electrosurgical blade 106. More particularly, switches126 a-126 c are electrically coupled to control loop 116 and areconfigured to close and/or complete control loop 116 to thereby permitRF energy to be transmitted to electrocautery blade 106 fromelectrosurgical generator “G.”

Activation switches 124 a-124 c are configured and adapted to controlthe mode and/or “waveform duty cycle” to achieve a desired surgicalintent in the same manner as activation switches 24 a-24 c ofelectrosurgical pencil 10 described above.

In operation and depending on the particular electrosurgical functiondesired, the surgeon depresses one of activation switches 124 a-124 c,in the direction indicated by arrow “Y” thereby closing a correspondingswitch 126 a-126 c and closing and/or completing control loop 116. Forexample, the surgeon can depress activation switch 124 a to perform acutting or dissecting function, activation switch 124 b to perform adissecting/hemostatic function, or activation switch 124 c to perform ahemostatic function. In turn, generator “G” transmits an appropriatewaveform output to electrocautery blade 106 via transmission wire 114.

In an alternative embodiment, as seen in FIGS. 5 and 6, slidingfrequency controller 135 has been replaced with frequency controllers235 a, 235 b in the form of dial-like VDNs. Frequency controllers 235 a,235 b function to vary the frequency of the RF energy waveform via arotation of dial controllers 235 a, 235 b in either a clockwise orcounter-clockwise direction as indicated by double headed arrow “Z”. Asseen in FIGS. 5 and 6, dial controllers 235 a, 235 b are disposedexternally of housing 102, however, dial controllers 235 a, 235 b may bedisposed within housing 102 with only a portion projecting therefrom formanipulation by the surgeon. In embodiments, frequency controllers 235a, 235 b may be a single controller having a pair of opposed knobs/dialsprovided, one each, on either side of housing 102. In this manner, thefrequency can be controlled from either side of electrosurgical pencil100. In the illustrated embodiment, frequency controllers 235 a, 235 bare shown positioned adjacent activation switches 124 a-124 c forillustrative purposes only and may be positioned anywhere along housing102 (e.g., proximal or distal to activation switches 124 a-124 c).Further, sliding intensity controllers 128 a, 128 b may be slidablysupported in guide channels 130 a and 130 b. Alternatively, intensitycontrollers 128 a, 128 b may be configured in either a “single-nub” or“double-nub” configuration and slidably supported in a guide channel(not explicitly shown) proximal or distal to activation switches 124a-124 c.

In alternative embodiments, sliding intensity controllers 128 a, 128 bmay be replaced with dial-like VDNs (not explicitly shown). In thisconfiguration, sliding frequency controller 135 may be configured ineither a “single-nub” or “double-nub” configuration and slidablysupported in a guide channel (not explicitly shown) proximal or distalto activation switches 124 a-124 c.

Since the surgeon has a number of controls at his finger tips, thesurgeon is able to create a pallet of varying therapeutic effectsranging from a pure “cutting” effect to a pure “coagulating” effect anda number of effects in between at a number of intensities and/orfrequencies. Moreover, with some pre-setting of the electrosurgicalenergy source “G”, electrosurgical pencil 100 will have all the usefulsettings available to the surgeon within the sterile field. Accordingly,it is not necessary that the surgeon interact with hardware outside thesterile field (e.g., electrosurgical energy source “G”) once thesurgical procedure begins thus allowing the surgeon to focus attentionon the surgical procedure.

While embodiments of electrosurgical pencils according to the presentdisclosure have been described herein, it is not intended that thedisclosure be limited there and the above description should beconstrued as merely exemplifications of preferred embodiments. Thoseskilled in the art will envision other modifications within the scopeand spirit of the present disclosure.

For example, as seen in FIG. 7, an alternative embodiment of anelectrosurgical pencil is shown generally as 200. Electrosurgical pencil200 is similar to electrosurgical pencil 10 and/or 100 and will only bediscussed in detail to the extent necessary to identify differences inconstruction and operation. As seen in FIG. 7, electrosurgical pencil200 includes a plurality of nubs 229 a-229 c, which are slidinglysupported, one each, in respective guide channels 230 a-230 c, formed inouter surface 7 of housing 2, at a position proximal of activationswitches 24 a-24 c. In embodiments, each nub 229 a-229 c is operativelyengaged with a slide potentiometer and may be configured and adapted toadjust the frequency parameter to affect the perceived RF output ofgenerator “G.” In an alternative embodiment, each nub 229 a-229 c isoperatively engaged with a slide potentiometer and may be configured andadapted to adjust the power parameters and/or the power verses impedancecurve shape to affect the perceived output intensity.

Accordingly, electrosurgical pencil 200 can be configured such that eachactivation switch 24 a-24 c is a separate mode, such as, for example,activation switch 24 a can be set such that electrosurgical pencil 200performs “division” when depressed, activation switch 24 b can be setsuch that electrosurgical pencil 200 performs “division with hemostasis”when depressed, and activation switch 24 c can be set such thatelectrosurgical pencil 200 performs “hemostasis” when depressed. Inaddition, each of nubs 229 a-229 c is in operative engagement with acorresponding activation switch 24 a-24 c such that the power/frequencyfor each mode of operation of electrosurgical pencil 200 can beindependently adjusted.

As seen in FIG. 8, nubs 229 a-229 c of electrosurgical pencil 200 havebeen replaced with toggles 231 a-231 c operatively engaged with arespective activation switch 24 a-24 c. Each toggle 231 a-231 c can beoperatively engaged with a rocker-type switch (not shown) or arotational dial (not shown) in place of the slide-type potentiometerdescribed above. Further, toggles 231 a-231 c may be configured andadapted to adjust the power parameters or, alternatively, the frequencyparameters to adjust the perceived output intensity and perceived outputfrequency, respectively.

Turning now to FIGS. 9-11, an electrosurgical pencil, in accordance withstill another embodiment of the present disclosure, is generallydesignated as 300. Electrosurgical pencil 300 is similar toelectrosurgical pencil 10 and/or 100 and will only be discussed indetail to the extent necessary to identify differences in constructionand operation. As seen in FIGS. 9 and 10, nubs 29 a, 29 b have beenreplaced with a dial 329 rotatably supported in an aperture 330 formedin outer surface 7 of housing 2. In embodiments, dial 329 may bepositioned forward of activation switch 24 a such that dial 329 is notinadvertently rotated during the depression of any one of activationswitches 24 a-24 c. Further, dial 329 may be configured and adapted toadjust the power parameters or, alternatively, the frequency parametersto adjust the perceived output intensity and perceived output frequency,respectively.

As seen in FIG. 9, a side surface 331 of dial 329 can be provided withindicia and/or markings “M” in the form of a scale and/or other form ofgradient to indicate to the surgeon the degree of and/or level ofpower/frequency at which electrosurgical pencil 300 is set.

As seen in FIGS. 10 and 11, windows 332 can be formed on either side ofdial 329 in outer surface 7 of housing 2. As seen in FIG. 11, windows332 provide the surgeon with visibility to indicia “M” provided on stub333 extending from the central axis of dial 329. Indicia “M” can be inthe form of numbers, letters, colors and, as seen in FIGS. 10 and 11, anenlarging gradient. In embodiments, each dial 329 may perform a dualfunction, for example, dial 329 can be rotated to set the desiredpower/frequency level and can be pressed down to activate theelectrosurgical pencil with the desired mode.

In embodiments, electrosurgical pencil 100 may include a smartrecognition technology that communicates with the generator to identifythe electrosurgical pencil and communicate various surgical parametersthat relate to treating tissue with electrosurgical pencil 100. Forexample, the electrosurgical pencil 100 may be equipped with a bar codeor Aztec code that is readable by the generator and presets thegenerator to default parameters associated with treating tissue withelectrosurgical pencils. The bar code or Aztec code may also includeprogrammable data that is readable by the generator and programs thegenerator to specific electrical parameters prior to use.

Other smart recognition technology may be included that enables thegenerator to determine the type of instrument being utilized or toinsure proper attachment of the instrument to the generator as a safetymechanism. One such safety connector is identified in U.S. Pat. No.7,131,860, the entire contents of which are incorporated herein byreference. For example, in addition to the smart recognition technologydescribed above, such a safety connector can include a plug or maleportion operatively associated with the electrosurgical pencil and acomplementary socket or female portion operatively associated with theelectrosurgical generator. Socket portion is “backward compatible” toreceive connector portions of electrosurgical pencils disclosed thereinand to receive connector portions of prior electrosurgical instruments.

While several embodiments of the disclosure have been shown in thedrawings and/or discussed herein, it is not intended that the disclosurebe limited thereto, as it is intended that the disclosure be as broad inscope as the art will allow and that the specification be read likewise.Therefore, the above description should not be construed as limiting,but merely as exemplifications of particular embodiments. Those skilledin the art will envision other modifications within the scope and spiritof the claims appended hereto.

The invention claimed is:
 1. An electrosurgical pencil, comprising: ahousing having an electrocautery electrode supported therein andextending distally therefrom, the electrocautery electrode adapted toconnect to a source of electrosurgical energy; at least one voltagedivider network electrically connected to the source of electrosurgicalenergy for controlling a frequency, a mode, and an intensity of theelectrosurgical energy delivered to the electrocautery electrode; aplurality of activation switches supported on the housing, eachactivation switch configured to activate the mode of the electrosurgicalenergy produced by the source of electrosurgical energy; and acontroller supported on the housing and operably coupled to the voltagedivider network, the controller disposed in operative communication withat least one of the plurality of activation switches, the controllerconfigured to adjust and vary the frequency of the electrosurgicalenergy delivered to the electrocautery electrode for the mode of theelectrosurgical energy activated by at least one of the plurality ofactivation switches, the voltage divider network configured to store aprevious operative frequency setting for each mode and to set thefrequency of the electrosurgical energy to the stored previous operativefrequency setting when a mode corresponding to the stored previousoperative frequency setting is activated.
 2. The electrosurgical pencilaccording to claim 1, wherein the controller is configured to vary thefrequency of the electrosurgical energy from a minimum of about 470 kHzto a maximum of about 1 MHz.
 3. The electrosurgical pencil according toclaim 1, wherein the controller is a slide potentiometer.
 4. Theelectrosurgical pencil according to claim 1, wherein the controller isdisposed proximal to the plurality of activation switches.
 5. Theelectrosurgical pencil according to claim 1, wherein the controller is atoggle disposed adjacent one of the plurality of activation switches. 6.The electrosurgical pencil according to claim 1, wherein the frequencyof the electrosurgical energy delivered to the electrocautery electrodefor each mode is independently controlled by the controller.
 7. Theelectrosurgical pencil according to claim 1, further including a secondcontroller supported on the housing and operably coupled to the voltagedivider network, the second controller disposed in operativecommunication with at least one of the activation switches andconfigured to control at least one electrical parameter of theelectrosurgical energy delivered to the electrocautery electrode for themode of the electrosurgical energy activated by at least one of theplurality of activation switches.
 8. An electrosurgical pencil,comprising: a housing having an electrocautery electrode supportedtherein and extending distally therefrom, the electrocautery electrodeadapted to connect to a source of electrosurgical energy; at least onevoltage divider network electrically connected to the source ofelectrosurgical energy for controlling a frequency, a mode, and anintensity of the electrosurgical energy delivered to the electrocauteryelectrode; a plurality of activation switches supported on the housing,each activation switch configured to activate the mode of theelectrosurgical energy produced by the source of electrosurgical energy;and a dial supported on the housing and operably coupled to the voltagedivider network, the dial configured to adjust and vary the frequency ofthe electrosurgical energy delivered to the electrocautery electrode forthe particular mode of the electrosurgical energy activated by at leastone of the plurality of activation switches, the voltage divider networkconfigured to store a previous operative frequency setting for each modeand to set the frequency of the electrosurgical energy to the storedprevious operative frequency setting when a mode corresponding to thestored previous operative frequency setting is activated.
 9. Theelectrosurgical pencil according to claim 8, wherein the housingincludes at least one window disposed proximate the dial, the windowconfigured to display indicia representative of a level of the frequencyof the electrosurgical energy delivered to the electrocautery electrode.10. The electrosurgical pencil according to claim 9, wherein the dialincludes a stub extending therefrom within the housing, the stub beingsubstantially aligned with the window and including the indicia thereon.11. The electrosurgical pencil according to claim 10, wherein theindicia on the stub is an enlarging gradient.
 12. The electrosurgicalpencil according to claim 8, wherein the dial is configured to vary thefrequency of the electrosurgical energy from a minimum of about 470 kHzto a maximum of about 1 MHz.
 13. The electrosurgical pencil according toclaim 8, wherein the dial includes indicia on a side thereof, theindicia representative of a level of the frequency of theelectrosurgical energy delivered to the electrocautery electrode. 14.The electrosurgical pencil according to claim 8, wherein the dialincludes a pair of opposed knobs disposed on opposite sides of thehousing.
 15. The electrosurgical pencil according to claim 8, furtherincluding a controller slidably supported on the housing and operablycoupled to the voltage divider network, the controller configured tocontrol the intensity of the electrosurgical energy delivered to theelectrocautery electrode for the mode.
 16. An electrosurgical pencil,comprising: a housing having an electrocautery electrode supportedtherein and extending distally therefrom, the electrocautery electrodeadapted to connect to a source of electrosurgical energy; at least onevoltage divider network electrically connected to the source ofelectrosurgical energy for controlling a frequency, a mode, and anintensity of the electrosurgical energy delivered to the electrocauteryelectrode; and at least one dual function dial supported on the housingand operably coupled to the voltage divider network, the dialselectively engagable with the voltage divider network to select themode of the electrosurgical energy delivered to the electrocauteryelectrode and rotatable to adjust and vary the frequency of theelectrosurgical energy delivered to the electrocautery electrode, thefrequency of the electrosurgical energy for the selected particular modebeing controlled by rotation of the dial, the voltage divider networkconfigured to store a previous operative frequency setting for each modeand to set the frequency of the electrosurgical energy to the storedprevious operative frequency setting when a mode corresponding to thestored previous operative frequency setting is activated.
 17. Theelectrosurgical pencil according to claim 16, wherein the dial isconfigured to vary the frequency of the electrosurgical energy from aminimum of about 470 kHz to a maximum of about 1 MHz.